Optical Articles Comprising Encapsulated Microlenses and Methods of Making the Same

ABSTRACT

The present disclosure includes optical articles comprising a lens having first and second lens surfaces and a protective layer having first and second protective surfaces that is coupled to the lens such that the first protective surface is disposed on the second lens surface. The optical article can comprise a plurality of convex or concave optical elements defined on the second lens surface or the first protective surface. The protective layer can have a maximum thickness larger than a maximum height of each of the optical elements such that the protective layer encapsulates the optical elements.

FIELD OF INVENTION

The present invention relates generally to optical articles and, moreparticularly but without limitation, to optical articles comprisingencapsulated optical elements.

BACKGROUND

Optical articles, such as lenses, can be used to correct refractiveerrors of the eye, such as, for example, myopia, hyperopia, presbyopia,and astigmatism. Some lenses include optical elements such asmicrolenses on the lens surface which can facilitate correction of theserefractive errors. For example, microlenses can provide a positiveaddition value to focus part of the incoming light in front of theretina and thereby control myopia evolution.

Microlenses are used in other applications as well. For example,microlenses are used in digital projectors, imaging devices, e.g.,photocopiers and mobile-phone cameras, microscopes, e.g., for uniformillumination, displays, and for improving light collection efficiency ofCCD arrays, among other applications.

Optical elements disposed on an outer lens surface may have limitedprotection and thus can be susceptible to damage. Some lenses include acoating, such as a hard coat or varnish, on the optical elements. Thesecoatings, however, may not provide adequate protection. Additionally,these conventional coatings can change the geometric shape and thus theoptical design of the optical elements. As a result, the opticalelements may no longer provide the optical target they were designed tomeet. Accordingly, there is a need in the art for optical articlesconfigured to provide adequate optical element protection withoutaltering the optical design thereof.

SUMMARY

The present optical articles address the need for improved opticalelement protection by providing a protective layer that fullyencapsulates optical elements, e.g., microlenses, of the opticalarticle. An optical article according to the invention is defined inclaim 1. The protective layer can have a maximum thickness that isgreater than a maximum height of each of the optical elements to achievefull encapsulation thereof, e.g., such that an outer surface of theoptical article does not reproduce the optical element shape. Theprotective layer can thereby protect the optical elements with minimal,if any, alteration to the optical design of the optical elements.Various protective layers are suitable for use in the present opticalarticles, including, for example, wafers, coatings, lenses, and glue.

Some of the present optical articles comprise a lens having opposingfirst and second lens surfaces and a protective layer having opposingfirst and second protective surfaces. The protective layer, in somearticles, is coupled to the lens such that the first protective surfaceis disposed on the second lens surface. Some articles comprise aplurality of convex or concave optical elements, e.g., microlenses. Insome articles, each of the optical elements defines a portion of thesecond lens surface, optionally when the lens comprises the opticalelements. In some articles, each of the optical elements defines aportion of the first protective surface, optionally when the protectivelayer comprises the optical elements.

Each of the optical elements, in some articles, has a maximum height,optionally measured in a direction perpendicular to the first protectivesurface, that is less than or equal to 0.1 millimeters (mm). In somearticles, each of the optical elements can have a diameter that is lessthan or equal to 2.0 mm. The protective layer, in some articles, has amaximum thickness, optionally measured in a direction perpendicular tothe first protective surface between the first and second protectivesurfaces, that is larger than the maximum height of each of the opticalelements. In some articles, the optical elements are encapsulated withina volume defined between the second protective surface and the firstlens surface. Other embodiments of the optical article according to theinvention are defined in claims 2-8.

Some of the present methods comprise moving first and second primarymold portions of a first mold from an open position to a closed positionin which the primary mold portions cooperate to define a first moldcavity, where each of the primary mold portions defines a moldingsurface. A method of forming an optical article according to theinvention is defined in claim 9. Some methods comprise introducing afirst moldable material into the first mold cavity and, optionally,setting the first moldable material to form a first optical memberhaving opposing first and second optical surfaces. In some methods, themolding surface of the second primary mold portion defines a pluralityof concave recesses or a plurality of convex protrusions such that thesecond optical surface defines a plurality of optical elements. In somemethods, each of the optical elements is convex, optionally when thesecond primary mold portion defines a plurality of concave recesses. Insome methods, each of the optical elements is concave, optionally whenthe second primary mold portions defines a plurality of convexprotrusions. Each of the optical elements, in some methods, has amaximum height, optionally measured in a direction perpendicular to thesecond optical surface, that is less than or equal to 0.1 mm. Each ofthe optical elements, in some methods, has a diameter that is less thanor equal to 2.0 mm.

Some methods comprise coupling a second optical member to the secondoptical surface. In some methods, the second optical member has amaximum thickness, optionally measured in a direction perpendicular tothe second optical surface between first and second surfaces of thesecond optical member, that is larger than the maximum height of each ofthe optical elements. In some methods, the optical elements areencapsulated within a volume defined between the second surface of thesecond optical member and the first optical surface. Other embodimentsof the method of forming an optical article according to the inventionare defined in claims 10-15.

The term “coupled” is defined as connected, although not necessarilydirectly, and not necessarily mechanically; two items that are “coupled”may be unitary with each other. The terms “a” and “an” are defined asone or more unless this disclosure explicitly requires otherwise. Theterm “substantially” is defined as largely but not necessarily whollywhat is specified—and includes what is specified; e.g., substantially 90degrees includes 90 degrees and substantially parallel includesparallel—as understood by a person of ordinary skill in the art. In anydisclosed embodiment, the term “substantially” may be substituted with“within [a percentage] of” what is specified, where the percentageincludes 0.1, 1, 5, and 10 percent.

The terms “comprise” and any form thereof such as “comprises” and“comprising,” “have” and any form thereof such as “has” and “having,”and “include” and any form thereof such as “includes” and “including”are open-ended linking verbs. As a result, an apparatus that“comprises,” “has,” or “includes” one or more elements possesses thoseone or more elements, but is not limited to possessing only thoseelements. Likewise, a method that “comprises,” “has,” or “includes” oneor more steps possesses those one or more steps, but is not limited topossessing only those one or more steps.

Any embodiment of any of the apparatuses, systems, and methods canconsist of or consist essentially of—rather thancomprise/include/have—any of the described steps, elements, and/orfeatures. Thus, in any of the claims, the term “consisting of” or“consisting essentially of” can be substituted for any of the open-endedlinking verbs recited above, in order to change the scope of a givenclaim from what it would otherwise be using the open-ended linking verb.

Further, a device or system that is configured in a certain way isconfigured in at least that way, but it can also be configured in otherways than those specifically described. The feature or features of oneembodiment may be applied to other embodiments, even though notdescribed or illustrated, unless expressly prohibited by this disclosureor the nature of the embodiments. Some details associated with theembodiments described above and others are described below.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings illustrate by way of example and not limitation.For the sake of brevity and clarity, every feature of a given structureis not always labeled in every figure in which that structure appears.Identical reference numbers do not necessarily indicate an identicalstructure. Rather, the same reference number may be used to indicate asimilar feature or a feature with similar functionality, as maynon-identical reference numbers. Views in the figures are drawn toscale, unless otherwise noted, meaning the sizes of the depictedelements are accurate relative to each other for at least the embodimentin the view.

FIG. 1A is a top view of a first embodiment of the present opticalarticles that comprises a lens having a plurality of optical elementsand a protective layer encapsulating the optical elements.

FIG. 1B is a sectional view of the optical article of FIG. 1A takenalong line 1B-1B.

FIG. 1C is an enlarged, partial sectional view of the optical article ofFIG. 1A.

FIGS. 2A-2D schematically illustrate a first mold used in some of thepresent methods to form a lens having a plurality of optical elements.

FIGS. 2E-2H schematically illustrate a second mold used in some of thepresent methods to form and couple a protective layer to encapsulate theoptical elements.

FIGS. 3A and 3B are sectional views of a second embodiment of thepresent optical articles having a second lens coupled to theencapsulating protective layer.

FIGS. 4A-4D schematically illustrate a third mold used in some of thepresent methods to form and coupled the second lens to the encapsulatingprotective layer.

FIGS. 5A and 5B are sectional views of a third embodiment of the presentoptical articles in which the encapsulated optical elements are definedby an inner surface of the protective layer.

FIGS. 6A and 6B schematically illustrate bending and inverting aprotective layer formed using the mold of FIGS. 2A-2D to produce theprotective layer of FIGS. 5A and 5B.

FIGS. 6C-6F schematically illustrate a second mold used in some of thepresent methods to form and couple a lens to the protective layer formedin FIGS. 6A and 6B.

FIGS. 7A and 7B are sectional views of a fourth embodiment of thepresent optical articles in which one or more coatings define theprotective layer.

FIGS. 8A and 8B are sectional views of a fifth embodiment of the presentoptical articles in which the protective layer comprises a glue thatadheres a second lens to the first lens.

FIGS. 9A and 9B are sectional views of a sixth embodiment of the presentoptical articles in which the protective layer comprises a glue thatadheres a film to the lens.

FIG. 10 is a sectional view of a seventh embodiment of the presentoptical articles in which the optical elements are each concave.

FIG. 11 is a sectional view of an eighth embodiment of the presentoptical articles in which some of the optical elements are convex andsome of the optical elements are concave.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring to FIGS. 1A-1C, shown is a first embodiment 10 a of thepresent optical articles. Optical article 10 a can comprise a lens 34having opposing first and second lens surfaces 42 a and 42 b and aprotective layer 38 that has opposing first and second protectivesurfaces 46 a and 46 b. Protective layer 38 can comprise, for example, awafer. Optical article 10 a can have any suitable shape; for example,the optical article can be spherical, toric, or aspherical. Toillustrate, optical article 10 a can have an inner surface 14, e.g.,defined by first lens surface 42 a, and an outer surface 18, e.g.,defined by second protective surface 46 b. Inner surface 14 can beconcave and outer surface 18 can be convex; in other embodiments,however, each of the inner and outer surfaces can be concave, convex, orplanar, based on the intended use for optical article 10 a.

Lens 34 can include optical elements 22, each of which can be anysuitable optical element, e.g., for refracting light, such as, forexample, a microlens, a Fresnel ring, and the like. Each of opticalelements 22 can be concave or convex and can define a portion of secondlens surface 42 b. As shown, each of optical elements 22 comprises amicrolens that is convex. At least a portion of a convex opticalelement, e.g., 22, can define a convex optical element surface, e.g.,50, and/or the convex optical element can have one or more portions thatproject outwardly from lens 34 (or from protective layer 38, if definedthereby as described in further detail below). If an optical element,e.g., 22, is concave, at least a portion of the optical element candefine a concave optical element surface, e.g., 50, and/or the concaveoptical element can have one or more portions that are recessed in lens34 (or in protective layer 38, if defined thereby as described infurther detail below).

Optical elements 22 can be arranged in any suitable manner. For example,optical elements 22 can be defined within a first area 26 that spansacross all or part of second lens surface 42 b. In some embodiments,second lens surface 42 b can have one or more second areas 30 having nooptical elements, e.g., in an area surrounded by first area 26 and/or atthe periphery of optical article 10 a. Each of optical elements 22 canhave a maximum height 54, e.g., measured in a direction perpendicular tofirst protective surface 46 a or second lens surface 42 b, that is lessthan or equal to 0.1 millimeters (mm), such as, for example, less thanor equal to or between any two of 100 micrometers (μm), 90 μm, 80 μm, 70μm, 60 μm, 50 μm, 40 μm, 30 μm, 20 μm, 10 μm, 5 μm, 1 μm, or smaller.Each of optical elements 22 can have a diameter 58 that is less than orequal to 2.0 mm, such as, for example, less than or equal to or betweenany two of 2.0 mm, 1.5 mm, 1.0 mm, 0.5 mm, 0.1 mm, 80 μm, 60 μm, 40 μm,20 μm, or smaller. And, without limitation, lens 34 can have a minimumthickness 68, measured between first and second lenses surfaces 42 a and42 b in a direction perpendicular to the second lens surface, than isgreater than or equal to 1 mm, such as for example, greater than orequal to or between any two of, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, or larger.

Protective layer 38 can be coupled to lens 34 such that first protectivesurface 46 a is disposed on second lens surface 42 b. Protective layer38 can fully encapsulate optical elements 22. For example, protectivelayer 38 can have a maximum thickness 62, e.g., measured in a directionperpendicular to first protective surface 46 a, that is larger thanmaximum height 54 of each of optical elements 22. Minimum thickness 64of protective layer 38 can also, in some embodiments, be larger thanmaximum height 54. To illustrate, and without limitation, maximumthickness 62 and/or minimum thickness 64 of protective layer 38 can begreater than or equal to 0.1 mm, such as, for example, greater than orequal to or between any two of 0.5 mm, 0.7 mm, 0.9 mm, 1.1 mm, 1.2 mm,1.4 mm, or larger, e.g., greater than or equal to 0.6 mm. Opticalelements 22 can thus be fully encapsulated within a volume 66 definedbetween second protective surface 46 b and first lens surface 42 a.Protective layer 38, by fully encapsulating optical elements 22, canprotect the optical elements with minimal, if any, alterations to theoptical design of the optical elements to promote improved optics inoptical article 10 a, compared to conventional protective coatings,which can change the geometric shape and thus the optical design of theoptical elements.

The addition value of optical elements 22 can depend at least in part onthe materials used in lens 34 and protective layer 38. For example, lens34 can comprise a higher-index material and protective layer 38 cancomprise a lower-index material having an index of refraction that islower than that of the higher-index material such that optical elements22 create a positive addition value, e.g., for myopia control.Alternatively, protective layer 38 can comprise the higher-indexmaterial and lens 34 can comprise the lower-index material such thatoptical elements 22 create a negative addition value, e.g., forhyperopia control. Suitable materials for lens 34 and/or protectivelayer 38 can include any optical material—such as, for example,polycarbonate, co-polyester, thermoplastic polyurethane, poly(methylmethacrylate), polyamide, bio-engineered polymers, cellulose triacetate,allyl diglycol carbonate, polyepisulfides, trivex, polyacrylics,polyols, polyamines, polyanhydrides, polycarboxilic acids, polyepoxides,polyisocyanates, polynorbornenes, polysiloxanes, polysilazanes,polystyrenes, polyolefinics, polyesters, polyimides, polyurethanes,polythiourethanes, polyallylics, polysulfides, polyvinylesters,polyvinylethers, polyarylenes, polyoxides, polysulfones, poly cycloolefins, polyacrylonitriles, polyethylene terephtalates,polyetherimides, polypentenes, and the like—having an appropriate indexof refraction for obtaining the desired optical element addition value.To illustrate, and without limitation, suitable lower-index materialscan have an index of refraction that is less than or equal to, orbetween any two of, 1.55, 1.54, 1.53, 1.52, 1.51, 1.50, 1.49, 1.48,1.47, 1.46, 1.45, or lower, e.g., less than or equal to 1.55, andsuitable higher-index materials can have an index of refraction that isgreater than or equal to or between any two of 1.55, 1.57, 1.59, 1.61,1.63, 1.65, 1.67, 1.69, 1.71, 1.73, 1.75, or higher, e.g., greater thanor equal to 1.59. Optionally, the difference between the indices ofrefraction of the lower- and higher-index materials is greater than orequal to 0.1. If optical elements 22 are concave, the effect of thedifferent indices of refraction between lens 34 and protective layer 38on the optical element addition value can be the opposite of thatdescribed above.

Some of the present methods for forming an optical article, e.g., 10a-10 h, comprise manufacturing a first optical member and coupling asecond optical member to the first optical member. The first opticalmember can be a lens, e.g., 34, and the second optical member can be aprotective layer, e.g., 38, e.g., as described below with reference toFIGS. 2A-2H. However, in other embodiments, the first optical member canbe the protective layer and the second optical member can be the lens,e.g., as described below with reference to FIGS. 6A-6F.

Referring to FIGS. 2A-2D, shown is a first mold, e.g., 70, suitable foruse in some of the present methods to manufacture a first opticalmember, e.g., lens 34 or protective layer 38, for one of the presentoptical articles, e.g., 10 a-10 h. The first mold can comprise first andsecond primary mold portions, e.g., 74 a and 74 b, each defining amolding surface, e.g., 78 a, 78 b, e.g., via mold inserts 82 a, 82 b.The molding surface of the second primary mold portion can define aplurality of concave recesses, e.g., 86, e.g., to form convex opticalelements, and/or a plurality of convex protrusions, e.g., to formconcave optical elements; as shown, the molding surface defines aplurality of concave recesses. Each of the molding surfaces can beconcave, convex, or planar, depending on the desired article shape; forexample, as shown, the molding surface of the first primary mold portionis convex, e.g., to form a concave optical surface, and the moldingsurface of the second primary mold portion is concave, e.g., to form aconvex optical surface.

Some of the present methods comprise moving the first and second primarymold portions from an open position (FIG. 2A) to a closed position (FIG.2B) in which the primary mold portions cooperate to define a first moldcavity, e.g., 90. To form a first optical member, e.g., lens 34 orprotective layer 38, some methods comprise introducing a first moldablematerial, e.g., 94, into the first mold cavity (FIG. 2C) and setting thefirst moldable material, e.g., by curing and/or cooling (FIG. 2D). Theforming can be performed via, for example, injection molding or casting.The resulting first optical member can have opposing first and secondoptical surfaces, e.g., first and second lens surfaces 42 a and 42 b, ifa lens, or first and second protective surfaces 46 a and 46 b, if aprotective layer, where the second optical surface defines a pluralityof optical elements, e.g., 22. Concave recesses and/or convexprotrusions, e.g., 86, of the second primary mold portion can be shapedand sized such that the optical elements defined on the second opticalsurface are shaped and sized as described above with respect to FIGS.1A-1C. As shown, the first mold is used to form a lens 34, e.g., ofoptical articles 10 a-10 b and 10 d-10 h. In other embodiments, however,the first mold can be used to produce protective layer 38, e.g., ofoptical article 10 c, described below.

Referring to FIGS. 2E-2H, shown is a second mold, e.g., 98 a, suitablefor use in some of the present methods to form and couple a secondoptical member, e.g., protective layer 38, to the second optical surfaceof the first optical member. The coupling can be performed such that thesecond optical member fully encapsulates the optical elements defined onthe second optical surface. The second mold can comprise first andsecond secondary mold portions, e.g., 102 a and 102 b, each defining amolding surface, e.g., 106 a, 106 b, e.g., via mold inserts 110 a, 110b. Each of the molding surfaces can be concave, convex, or planar,depending on the desired article shape; for example, as shown, themolding surface of the first primary mold portion is convex, e.g., toreceive the concave first optical surface, and the molding surface ofthe second primary mold portion is concave, e.g., to form a convexoptical surface.

Some of the present methods comprise placing the first optical member onthe second mold such that the first optical surface is disposed on themolding surface of the first secondary mold portion. After the placing,some methods comprise moving the first and second secondary moldportions from an open position (FIG. 2E) to a closed position (FIG. 2F)in which the secondary mold portions cooperate to define a second moldcavity, e.g., 114. The second mold cavity can be larger than the firstoptical member such that a volume, e.g., 118, is defined between themolding surface of the second secondary mold portion and the secondoptical surface. To form and couple the second optical member to thefirst optical member, some methods comprise introducing a secondmoldable material, e.g., 122, into the volume (FIG. 2G) and setting thesecond moldable material, e.g., by curing and/or cooling (FIG. 2H). Theforming can be performed via injection molding or casting. The resultingsecond optical member can be coupled to the second optical surface andcan have a thickness, e.g., measured in a direction perpendicular to thesecond optical surface between first and second surfaces of the secondoptical member, that is larger than the maximum height of each of theoptical elements such that the second optical member fully encapsulatesthe optical elements, e.g., such that the optical elements areencapsulated within a volume defined by the second surface, e.g., 46 b,and the first optical surface, e.g., 42 a. As shown, the second mold isused to form a protective layer 38 on lens 34, e.g., as in opticalarticles 10 a-10 b and 10 d-10 h, which can be, for example, a wafer asdescribed in reference to optical article 10 a.

The first and second moldable materials can be any suitable moldablematerial of optical quality, e.g., any of those described above, and canbe selected such that the optical elements provide the desired additionvalue. For example, as shown, the first moldable material, and thus,e.g., lens 34, can have a first index of refraction and the secondmoldable material, and thus, e.g., protective layer 38, can have asecond index of refraction lower than the first index of refraction suchthat the optical elements provide a positive addition value, e.g., formyopia control, or vice versa such that the optical elements provide anegative addition value, e.g., for hyperopia control.

Manufacturing and coupling the first and second optical members, e.g.,lens 34 and protective layer 38, by injection molding or casting canfacilitate reliable encapsulation of the optical elements with minimal,if any, impact on the optical design of the optical elements.

Referring to FIGS. 3A and 3B, shown is an optical article 10 b that issubstantially similar to optical article 10 a, the primary exceptionbeing that optical article 10 b comprises a second lens 126. Second lens126 can have opposing inner and outer second lens surfaces 130 a and 130b and can be coupled to protective layer 38 such that inner second lenssurface 130 a is disposed on second protective surface 46 b. Forexample, outer second lens surface 130 b can define outer surface 18 ofoptical article 10 b. Optionally, one or more coatings can be disposedon second lens 126, e.g., on outer second lens surface 130 b, such as,for example, a scratch-resistant coating, an antireflective coating,and/or any of the coatings described below in reference to opticalarticle 10 d. Second lens 126 can provide additional protection foroptical elements 22 and can contribute to the addition power of opticalarticle 10 b. Optionally, second lens 126 can comprise the same materialas lens 34. While second lens 126 is described as a lens, the secondlens can be any suitable optical member, such as, for example, a waferor a shell.

Some of the present methods comprise forming and coupling a thirdoptical member, e.g., second lens 126, to the second optical member,e.g., protective layer 38. Referring to FIGS. 4A-4D, shown is a thirdmold, e.g., 134, suitable for use in some of the present methods to forma third optical member. The third mold can have first and secondtertiary mold portions, e.g., 138 a and 138 b, each defining a moldingsurface, e.g., 142 a, 142 b, e.g., via mold inserts 146 a, 146 b. Eachof the molding surfaces can be concave, convex, or planar, depending onthe desired article shape. For example, as shown, the molding surface ofthe first tertiary mold portion is convex, e.g., to receive the concavefirst optical surface, and the molding surface of the second tertiarymold portion is concave, e.g., to form a convex optical surface.

Some of the present methods comprise placing the first and secondoptical members on the third mold such that the first optical surface,e.g., first lens surface 42 a, is disposed on the molding surface of thefirst tertiary mold portion. After the placing, some methods comprisemoving the first and second tertiary mold portions from an open position(FIG. 4A) to a closed position (FIG. 4B) in which the tertiary moldportions cooperate to define a third mold cavity, e.g., 150. The thirdmold cavity can be larger than the first and second optical members suchthat a volume, e.g., 154, is defined between the second surface, e.g.,second protective surface 46 b, of the second optical member and themolding surface of the second tertiary mold portion. To form and couplethe third optical member to the second optical member, some methodscomprise introducing a third moldable material, e.g., 158, into thevolume (FIG. 4C) and setting the third moldable material, e.g., bycuring and/or cooling (FIG. 4D). Optionally, the first moldable materialis the same as the third moldable material. The forming can be performedvia, for example, injection molding or casting, and the resulting thirdoptical member can be coupled to the second optical member, e.g., toproduce optical article 10 b.

Referring to FIGS. 5A and 5B, shown is an optical article 10 c that issubstantially similar to optical article 10 a, the primary exceptionbeing that protective layer 38—rather than lens 34—comprises opticalelements 22, e.g., such that each of the optical elements defines aportion of first protective surface 46 a. For example, as with opticalarticle 10 a, maximum thickness 62 of protective layer 38 can be largerthan maximum height 54 of each of optical elements 22 such that theprotective layer encapsulates the optical elements, e.g., the opticalelements are encapsulated within a volume 66 defined between secondprotective surface 42 b and first lens surface 42 a. And, as shown, eachof optical elements 22 is convex (e.g., can have an optical elementsurface 50 that is convex); however, in other embodiments, each of theoptical elements can be concave (e.g., can have an optical elementsurface that is concave). Because convex optical elements 22 are definedon first protective surface 46 a, e.g., are inverted compared to theoptical elements of optical article 10 a, the materials used in lens 34and protective layer 38 can affect the addition value of the opticalelements differently than for optical article 10 a. For example, asshown, optical elements 22 can provide a positive addition value, e.g.,for myopia control, when protective layer 38 is manufactured from ahigher-index material and lens 34 is manufactured from a lower-indexmaterial having an index of refraction lower than that of thehigher-index material. Alternatively, optical elements 22 can provide anegative addition value, e.g., for hyperopia control, when protectivelayer 38 is manufactured from the lower-index material and lens 34 ismanufactured from the higher-index material.

As shown, second protective surface 46 b of protective layer 38 definesouter surface 18 of optical article 10 c. In other embodiments, however,the optical article can comprise one or more additional layers coupledto second protective surface 46 b, such as, for example, a second lens,e.g., 126, as described in reference to optical article 10 b. Some ofsuch embodiments—e.g., when optical elements 22 are concave—can besubstantially similar to optical article 10 b.

In some methods, a protective layer, e.g., 38, having optical elements,e.g., 22, defined on its first protective surface, e.g., 46 a, can beformed with the first mold as described in reference to FIGS. 2A-2D.Referring to FIGS. 6A and 6B, the first mold, as it is shown in FIGS.2A-2D, can produce a first optical member, e.g., protective layer 38,having a convex second optical surface, e.g., first protective surface46 a, and a concave first optical surface, e.g., second protectivesurface 46 b (FIG. 6A). Some methods comprise bending and thereby, e.g.,permanently, inverting the first optical member such that the firstoptical surface, e.g., 46 b, is convex and the second optical surface,e.g., 46 a, is concave (FIG. 6B). The maximum thickness, e.g., 62, ofthe protective layer can be less than or equal to 1.5 mm, such as, forexample, less than or equal to or between any two of 1.5 mm, 1.4 mm, 1.3mm, 1.2 mm, 1.1 mm, 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, or less,e.g., less than or equal to 1.0 mm or 0.7 mm, such that the protectivelayer has sufficient flexibility for the bending. As such, the firstmold can be used to produce a protective layer having its opticalelements defined on the concave first protective surface, e.g., as inoptical article 10 c, without the need for different mold inserts,thereby reducing costs and tooling requirements. In other embodiments,the protective layer, e.g., of optical article 10 c, can be formed usingdifferent mold inserts than those shown in FIGS. 2A-2D. For example,different mold inserts can be used such that the concave recesses, e.g.,86, are defined on the convex molding surface of the first primary moldportion, rather than on the concave molding surface of the secondprimary mold portion.

Referring to FIGS. 6C-6F, shown is a second mold, e.g., 98 b, that issubstantially similar to second mold 98 a and that can be used in somemethods to form and couple a second optical member, e.g., lens 34, tothe first optical member, e.g., protective layer 38. The primarydifference between second molds 98 a and 98 b is that, for second mold98 b, the molding surface of the first secondary mold portion isconcave, e.g., to receive the convex first optical surface, e.g., secondprotective surface 46 b, and the molding surface of the second secondarymold portion is convex.

Encapsulation of the optical elements, e.g., 22, defined on the concavesecond optical surface, e.g., first protective surface 46 a, can beachieved in substantially the same manner as described above withreference to FIGS. 2E-2H. Some methods comprise placing the firstoptical member on the second mold such that the first optical surface,e.g., second protective surface 46 b, is disposed on the molding surfaceof the first secondary mold portion. After the placing, some methodscomprise moving the first and second secondary mold portions from anopen position (FIG. 6C) to a closed position (FIG. 6D) in which thesecondary mold portions cooperate to define a second mold cavity, e.g.,114. The second mold cavity can be larger than the first optical member,e.g., protective layer 38, such that a volume, e.g., 118, is definedbetween the molding surface of the second secondary mold portion and thesecond optical surface, e.g., first protective surface 46 a. To form andcouple the second optical member, e.g., lens 34, to the first opticalmember, some methods comprise introducing a second moldable material,e.g., 122, into the volume (FIG. 6E) and setting the second moldablematerial, e.g., by curing and/or cooling (FIG. 6F). The forming can beperformed via, e.g., injection molding or casting. The resulting secondoptical member, e.g., lens 34, can be coupled to the concave secondoptical surface, e.g., first protective surface 46 a, of the firstoptical member, e.g., protective layer 38.

In some methods, a third optical member, e.g., second lens 126, can beformed and coupled to the first optical surface, e.g., second protectivesurface 46 b, in substantially the same manner as described above withreference to FIGS. 4A-4D. In other methods, however, the second andthird optical members can be coupled to the second and first opticalsurfaces, respectively, with a single mold, e.g., by introducing andsetting moldable material in volumes defined by the mold on either sideof the first optical member.

Referring to FIGS. 7A and 7B, shown is an optical article 10 d that issubstantially similar to optical article 10 a, the primary exceptionbeing that protective layer 38 comprises one or more coatings, e.g., 162a-162 b, that, collectively, fully encapsulate optical elements 22. Atleast one of, optionally each of, the coating(s) can comprisepolyurethane coating, a scratch-resistant coating, an antireflectivecoating, a photochromic coating, an anti-smudge coating, an anti-fogcoating, a tintable coating, a self-healing coating, an anti-raincoating, an anti-static coating, an anti-UV coating, or an anti-bluelight coating. As shown, protective layer 38 comprises three coatings162 a-162 c, where a polyurethane coating 162 a is disposed on secondlens surface 42 b, a scratch-resistant coating, e.g., hard coating, 162b is disposed on the polyurethane coating, and an anti-reflectivecoating 162 c is disposed on the scratch-resistant coating. Otherembodiments, however, can comprise any suitable number of coatings, ofany type, arranged in any suitable order.

Unlike conventional coatings, the present coating(s) can be applied tosecond lens surface 42 b such that the protective layer 38 defined bythe coating(s) fully encapsulates optical elements 22, e.g., asdescribed with reference to FIGS. 1A-1C, and causes minimal, if any,alterations to the optical design of the optical elements. For example,each of the coating(s) can have a respective maximum thickness, e.g., 62a-62 c, where the maximum thicknesses collectively are larger thanmaximum height 54 of each of optical elements 22. Each of the coatings,for example, can have a maximum thickness, e.g., 62 a-62 c, that isgreater than or equal to, or between any two of, 1 μm, 5 μm, 10 μm, 20μm, 30 μm, 40 μm, 50 μm, 60 μm, or larger, e.g., greater than or equalto 15 μm. The maximum thickness, e.g., 62 a, of the coating, e.g., 162a, disposed on second lens surface 42 b can, but need not, be greaterthan maximum height 54 of each of optical elements 22. The presentcoatings can thus define a protective layer 38 that can protect opticalelements 22 and impart beneficial optical properties on optical article10 e, such as, for example, photochromic properties, anti-reflectiveproperties, fog resistance, tinting, moisture resistance, and/or thelike.

Referring to FIGS. 8A-8B, shown is an optical article 10 e that issubstantially similar to optical article 10 b, the primary exceptionbeing that protective layer 38 comprises glue coupling and/or adheringsecond lens 126 to lens 34. The glue can comprise any optically suitableadhesive, such as, for example, an adhesive capable of conveying visibleand/or ultraviolet light therethrough, e.g., a UV adhesive.Additionally, or alternatively, the glue can comprise one or morecoatings, e.g., any of those described above, which can be cured andcouple second lens 126 to lens 34. For example, such coating(s) can bedeposited on second lens surface 42 b and cured, e.g., to encapsulateoptical elements 22, and second lens 126 can be molded onto secondprotective surface 46 b of the coating(s), e.g., as described above. Theglue can have an index of refraction that is less than that of lens 34such that optical elements 22 provide a positive addition value, or thatis greater than that of the lens such that the optical elements providea negative addition value.

Referring to FIGS. 9A-9B, shown is an optical article 10 f that issubstantially similar to optical article 10 e, the primary exceptionbeing that, instead of second lens 126, a film 166 is disposed on secondprotective surface 46 b and is adhered to lens 34 via the glue ofprotective layer 38. Film 166 can provide protection for opticalelements 22.

While each of optical articles 10 a-10 f, as shown, only has convexoptical elements 22, other embodiments can have concave opticalelements. For example, referring to FIG. 10, optical article 10 g can besubstantially similar to optical article 10 a, the primary exceptionbeing that optical article 10 g comprises concave optical elements 22(e.g., that each have a concave optical element surface 50), and,optionally, inner surface 14 can be convex and outer surface 18 can beconcave. Optical article 10 g can provide a negative addition value to,for example, control hyperopia, and its lens 34 can be formed, forexample, in a first mold, e.g., 70, having a molding surface with convexprotrusions, e.g., 86. Referring to FIG. 11, optical article 10 h can besubstantially similar to optical article 10 a, the primary exceptionbeing that some of optical elements 22 of optical article 10 a areconvex (e.g., have a convex optical element surface 50) and some of theoptical elements are concave (e.g., have a concave optical elementsurface). Optical article 10 h can be suitable to control, e.g.,astigmatism, and its lens 34 can be formed, for example, in a firstmold, e.g., 70, having a molding surface with both convex protrusionsand concave recesses, e.g., 86.

The above specification and examples provide a complete description ofthe structure and use of illustrative embodiments. Although certainembodiments have been described above with a certain degree ofparticularity, or with reference to one or more individual embodiments,those skilled in the art could make numerous alterations to thedisclosed embodiments without departing from the scope of thisinvention. As such, the various illustrative embodiments of the methodsand systems are not intended to be limited to the particular formsdisclosed. Rather, they include all modifications and alternativesfalling within the scope of the claims, and embodiments other than theone shown may include some or all of the features of the depictedembodiment. For example, elements may be omitted or combined as aunitary structure, and/or connections may be substituted. Further, whereappropriate, aspects of any of the examples described above may becombined with aspects of any of the other examples described to formfurther examples having comparable or different properties and/orfunctions, and addressing the same or different problems. Similarly, itwill be understood that the benefits and advantages described above mayrelate to one embodiment or may relate to several embodiments.

The claims are not intended to include, and should not be interpreted toinclude, means-plus- or step-plus-function limitations, unless such alimitation is explicitly recited in a given claim using the phrase(s)“means for” or “step for,” respectively.

1. An optical article comprising: a lens having opposing first andsecond lens surfaces; a protective layer having opposing first andsecond protective surfaces and a maximum thickness, measured in adirection perpendicular to the first protective surface between thefirst and second protective surfaces, the first protective surfacedisposed on the second lens surface; and a plurality of convex orconcave optical elements, each: defining a portion of one of the firstprotective surface and the second lens surface; and having a maximumheight, measured in a direction perpendicular to the first protectivesurface, that is less than or equal to 0.1 millimeters (mm) and adiameter that is less than or equal to 2.0 mm; wherein the maximumthickness of the protective layer is larger than the maximum height ofeach of the optical elements such that the optical elements areencapsulated within a volume defined between the second protectivesurface and the first lens surface.
 2. The optical article of claim 1,wherein the lens comprises the optical elements such that each of theoptical elements defines a portion of the second lens surface.
 3. Theoptical article of claim 2, wherein: the lens comprises a first materialhaving a first index of refraction; and the protective layer comprises asecond material having a second index of refraction lower than the firstindex of refraction.
 4. The optical article of claim 2, wherein: theprotective layer comprises glue; and the optical article comprises afilm disposed on the second protective surface.
 5. The optical articleof claim 2, wherein the protective layer comprises one or more coatings,at least one of the coating(s) comprising a polyurethane coating, ascratch-resistant coating, an antireflective coating, a photochromiccoating, an anti-smudge coating, an anti-fog coating, a tintablecoating, a self-healing coating, an anti-rain coating, an anti-staticcoating, an anti-UV coating, or an anti-blue light coating.
 6. Theoptical article of claim 1, wherein the protective layer comprises theoptical elements such that each of the optical elements defines aportion of the first protective surface.
 7. The optical article of claim6, wherein the lens comprises a first material having a first index ofrefraction; and the protective layer comprises a second material havinga second index of refraction higher than the first index of refraction.8. The optical article of claim 1, wherein: each of the optical elementsis convex; the second protective surface is convex; and the firstprotective surface is concave.
 9. A method of forming an opticalarticle, the method comprising: moving first and second primary moldportions of a first mold from an open position to a closed position inwhich the primary mold portions cooperate to define a first mold cavity,each of the primary mold portions defining a molding surface;introducing a first moldable material into the first mold cavity;setting the first moldable material to form a first optical memberhaving opposing first and second optical surfaces, wherein the moldingsurface of the second primary mold portion defines a plurality ofconcave recesses or a plurality of convex protrusions such that thesecond optical surface defines a plurality of convex or concave opticalelements, each having: a maximum height, measured in a directionperpendicular to the second optical surface, that is less than or equalto 0.1 millimeters (mm); and a diameter that is less than or equal to2.0 mm; and coupling a second optical member to the second opticalsurface, the second optical member having a maximum thickness, measuredin a direction perpendicular to the second optical surface between firstand second surfaces of the second optical member, that is larger thanthe maximum height of each of the optical elements such that the opticalelements are encapsulated within a volume defined between the secondsurface of the second optical member and the first optical surface. 10.The method of claim 9, wherein the coupling comprises: placing the firstoptical member on a second mold comprising first and second secondarymold portions such that the first optical surface is disposed on amolding surface of the first secondary mold portion; after the placing,moving the secondary mold portions from an open position to a closedposition in which the secondary mold portions cooperate to define asecond mold cavity that is larger than the first optical member suchthat a volume is defined between the second optical surface and amolding surface of the second secondary mold portion; introducing asecond moldable material into the volume; and setting the secondmoldable material to form the second optical member such that the secondoptical member is coupled to the first optical member and encapsulatesthe optical elements.
 11. The method of claim 10, comprising: placingthe first and second optical members on a third mold comprising firstand second tertiary mold portions such that the first optical surface isdisposed on a molding surface of the first tertiary mold portion; afterthe placing, moving the tertiary mold portions from an open position toa closed position in which the tertiary mold portions cooperate todefine a third mold cavity, wherein the third mold cavity is larger thanthe first and second optical members such that a volume is definedbetween the second surface of the second optical member and a moldingsurface of the second tertiary mold portion; introducing a thirdmoldable material into the volume; and setting the third moldablematerial to form a third optical member that is coupled to and disposedon the second surface of the second optical member; wherein the thirdmoldable material is the same as the first moldable material.
 12. Themethod of claim 10, wherein: the molding surface of the first primarymold portion is convex such that the first optical surface is concave;and the molding surface of the second primary mold portion: is concavesuch that the second optical surface is convex; and defines a pluralityof concave recesses such that each of the optical elements is convex.13. The method of claim 12, comprising, before placing the first opticalmember on the second mold, bending and thereby inverting the firstoptical member such that the first optical surface is convex and thesecond optical surface is concave.
 14. The method of claim 12, whereinthe first moldable material has a first index of refraction and thesecond moldable material has a second index of refraction lower than thefirst index of refraction.
 15. The method of claim 9, wherein thecoupling comprises applying one or more coatings to the second opticalsurface such that the coating(s) define the second optical member, atleast one of the coating(s) comprising a polyurethane coating, ascratch-resistant coating, an antireflective coating, a photochromiccoating, an anti-smudge coating, an anti-fog coating, a tintablecoating, a self-healing coating, an anti-rain coating, an anti-staticcoating, an anti-UV coating, or an anti-blue light coating.